ACE20 and ACE30 Variable Frequency Drive System

Transcription

1 ACE20 and ACE30 Variable Frequency Drive System Installation & Maintenance Information IF 1660 SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE Blower Cooling Intake Shroud Data Nameplate, including Torque Information Manifold Blower Warning Nameplate Baffle Terminal Block Control Pad Transformer Temperature Controller WIM Fan Communication Module VFD Control Pad Viewing Window Product Nameplate with Critical Markings Explosionproof Filter (pre-filters removed for clarity) Disconnect Operating Handle Pushbutton Start/Stop (not shown) Potentiometer Blower Fuse Block (not shown) External Ground Internal Ground Disconnect Switch Hand-Off-Auto Selector Switch (not shown) Warning Plate table of contents 1. Safety Instructions 1.1 Application Page Electrical Safety Page Blower Safety Page Hot Surfaces Page Enclosure Safety Page 3 2. Mechanical Installation 2.1 Airflow Provisions - Installation Drawing Page Weights Page Lifting Page Dimensional Drawings Page Mounting Page Shroud Installation Page Pre-filter Installation Page 5 3. Electrical Installation 3.1 Enclosure Grounding - Internal/External Page Line Feed Page Load Feed and Shield Grounding to Drive Page Control Wire Routing Page Blower and Signal Schematic Page 6 4. General Operation 4.1 Control Pad Viewing Window Page Disconnect and Lockout/Tagout Page Communication Modules Page POT, RR3 (HOA), and PB23 (Pushbutton Start/Stop) Page 12 Pre-filters 5. Maintenance 5.1 Drive Maintenance Page Cooling System Maintenance Page Periodic Mechanical Maintenance (Torque Verification) Page Status Indication Page Explosive Event Required Maintenance Page Technical Data 6.1 Technical Data Chart Page Power Loss (Heat Dissipation) Page Derating Factors and Curves (Ambient Temperature, Altitude, Switching Frequency) Page Crouse-Hinds Drive Parameters 7.1 Parameter Table Page Replacement Parts 8.1 Pre-filter Kit Page Pre-filter Installation Instructions Page Sintered Filter Kit Page Sintered Filter Installation Instructions Page Blower Kit Page Blower Installation Instructions Page Temperature Controller Kit Page Temperature Controller Installation Instructions Page 16 IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 1

2 1. safety instructions The ACE Explosionproof VFD should be installed, inspected, and maintained by qualified and competent personnel. 1.1 application The ACE Explosionproof VFD is rated Class I, Divisions 1 and 2 for use in hazardous environments, and is designed to match the strict requirements of pumps, compressors, fans, separators, and mixers in such process industries as: Oil and gas / refineries OEM skid builders Petrochemical Water / wastewater Pharmaceutical Food and beverage manufacturing 1.2 Electrical safety warning: high voltage Electrical power must be OFF before and during inspection or service. Ensure electrical supply to the enclosure is disconnected, locked out and tagged out. Personnel injury or damage to equipment can occur if all power upstream from the enclosure is not fully disconnected prior to opening. Before commissioning the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the line power. warning To avoid cooling system malfunction, cooling system failure, and personnel injury, remove all loose debris and deposits before energizing. These blowers comply with EN safety standards. The blower is non-serviceable. Refer to ACE KIT 3, Section 8.3, for replacement instructions. 1.4 hot surfaces WARNING: burn hazard To avoid personnel injury, use appropriate personnel protective equipment before handling and operating the device. caution To ensure safety and VFD performance, grounding provisions for the enclosure, blower, and VFD must be made before operating. 1.3 blower safety warning To avoid cooling system malfunction, cooling system failure, and personnel injury, close and seal the enclosure before energizing. Filter Shrouds Blower Intake warning: high speed To avoid personnel injury, DO NOT handle the blower or service the enclosure while energized. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 2

3 1.5 enclosure safety warning To avoid personnel injury and property damage, clean dirt and debris from flat ground joint surfaces before the cover is closed. NEVER energize this equipment if the flat ground joint has been scratched or damaged. All pipe threaded connections into the enclosure require a minimum of five (5) full threads of engagement. All straight threaded connections into the enclosure require a minimum of eight (8) full threads of engagement. Personnel injury or equipment damage can result from threaded joints containing less than the minimum thread engagement required. 2. mechanical installation 2.1 airflow provisions - installation drawing "X" All unused conduit openings must be plugged. UL Listed plug must engage a minimum of five (5) full threads and be a minimum of 1/8 thick. Conduit sealing fittings MUST be installed in each attached conduit run (within eighteen (18) inches of the enclosure) to comply with the latest edition of the National Electrical Code (NEC) plus any other applicable code. The cover must be properly fastened to the body with all cover bolts torqued to ft.-lbs. ( N-m). Personnel injury or equipment damage can result if the flat joint flame path is not properly fastened. Wireless Interface Module (WIM) offered with ACE20 (Rockwell VFD) must be used with precaution. If the device communicating to the WIM is exposed to the hazardous environment during operation, it must be rated and certified for the area of intended use. For the device used to communicate to the WIM, refer to the manufacturer s instructions on acceptable use. 3 5 warning To avoid cooling system malfunction and personnel injury, be sure to torque the first eight (8) cover screws sequentially per Figure 1 before torquing the remaining screws weights 1. Remove top and sides from shipping crate. 2. Remove lag bolts from enclosure mounting feet. "X" It is imperative that the enclosure be well ventilated to ensure reliable performance. Adequate space around the intake and exhaust of the enclosure MUST be accommodated. Crouse-Hinds recommends x be a minimum of 12 inches (0.3 meters). 2.3 lifting Enclosure Weight 1-5 HP 390 lbs HP 600 lbs. caution Do not attach shrouds or pre-filters until after enclosure is mounted Figure 1 warning To avoid personnel injury and property damage, DO NOT remove or modify the control pad viewing window. caution: unbalanced load To avoid personnel injury, utilize the dedicated lifting eye and handle appropriately to ensure safe installation. 3. Use the dedicated lifting eye to mount enclosure on suitable mounting surface. Select a mounting location that will provide suitable strength and rigidity for supporting the enclosure and all components. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 3

4 2.4 dimensional drawings /8" BOLT (4 PLACES) " NPT /2" NPT (2 PLACES) ACE Size /8" BOLT (4 PLACES) " NPT ACE Size mounting 1. Select a mounting location that will provide suitable strength, rigidity, and space (per Section 2.1) for supporting the ACE Series system and all contained wiring. caution To avoid cooling system malfunction, cooling system failure, and personnel injury, be sure to mount the enclosure as depicted in Section 2.4. caution To avoid cooling system malfunction, cooling system failure, and personnel injury, be sure to mount the enclosure in a shaded area to avoid direct sunlight. 2. Refer to Section 2.2 for approximate weights and Section 2.4 for dimensions. 3. Install two (2) 5/8 bolts on left side. 4. Tap each of the four (4) mounting feet with a mallet to ensure tight assembly. 5. Align enclosure with the two left side mounting feet engaged with the mounting bolts on selected mounting surface. 6. Tighten two (2) bolts on left side. 7. Install two (2) 5/8 bolts on right side and tighten. 2.6 SHROUD installation 1. Remove rubber caps from explosionproof filters. 2. Insert threaded rods into the explosionproof filters. Leave of threaded rod exposed. 3. Place shroud over explosionproof filters and threaded rod, with shroud opening facing back of enclosure. See Figure Insert washer and nuts onto end of threaded rod and tighten securely until shroud is firmly contacting the top wall of the enclosure. See Figure 3. THREADED STUD 8. After enclosure is positioned and secured in its permanent location, pull wires into the ACE Series system, making sure that they are long enough to make the Figure 2 required connections. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 4 2" NPT (2 PLACES)

5 ACORN NUT LOCKING NUT WASHER 3. electrical installation 3.1 enclosure grounding - internal/external Grounding and bonding of the conduit and equipment is required by the National Electrical Code. A grounding conductor must be connected to the grounding lugs furnished. Determine the type of distribution systems to be used that will comply with NEC requirements and ensure grounding continuity. Figure 3 All conductive equipment that enclose the electrical conductors or attached equipment or forming part of such equipment must be grounded. A permanent connection must be made between all such equipment and the earth. Refer to Section 5.3 for the torque requirements of all terminations within this device. 2.7 pre-filter installation 1. Remove rubber caps from explosionproof filters. 2. Install wire guard using the bracket, screw, and lock washer provided to the bottom filter(s). 3. Align guard with notches within the bracket as shown. 3.2 line feed Notch Disconnect Terminal Shrouds Bracket Guard Detail View 4. Tighten screw. 5. Slip pre-filter mesh over guard. This equipment is designed for line connection directly to the integral disconnect switch. Factory wiring transmits power to the variable frequency drive. 1. Remove disconnect terminal shrouds (only required on HP units). 2. Attach line conductors with phase A on the left, B center, and C to the right (see torque table in Section 5.3). 3. Re-install terminal shrouds (only required on HP units). 3.3 load feed and shield grounding to drive 6. Be sure to stretch pre-filter elastic band completely around the explosionproof filter and seat the elastic band on the filter s threads. This will ensure all air flow to the bottom filters passes through the pre-filters. Explosionproof Filter This equipment is designed for load connection directly from the variable frequency drive, although, in the case of an oversized VFD for the given motor, use the VFD and motor manufacturer s recommendations for proper motor overload protection. In certain cases, it is required to include additional motor overload protection between the VFD and the motor for proper motor overload protection. Always be sure to shield load wiring from line and control wiring to reduce noise. Refer to the drive manufacturer s manual for further details. 1. Attach load conductors with phase A to W/T1, B to V/T2, and C to W/T3 (see torque table in Section 5.3). 2. Attach motor cable shielding to VFD ground (see recommendations by drive manufacturer). 3. Refer to the drive manufacturer s manual for further information regarding drive installation. caution Failure to add additional motor overload protection between the VFD and motor when required can cause motor failure and equipment damage. 3.4 control wire routing To avoid the transmission of noise to/from the blower, control system, and/or the variable frequency drive load conductors, be sure to bundle all field control wiring and shield as necessary. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 5

6 BLACK BLACK PILOT LIGHT GREEN PILOT LIGHT WHITE WHITE L1 L2 L3 VARIABLE FREQUENCY DRIVE I/O T1 T2 T3 FIELD LOAD WIRING PE L1 L2 BLOWER L3 W/ GREEN STRIPE THIS SIDE OF S FACING BLOWER DIN RAIL MOUNTED S 1-6 WIRING FOR SIZE 2 ENCLOSURE ONLY NOT REQUI ON SIZE 1 ENCLOSURE (1) (2) (3) (4) ORANGE (5) (5) THIS SIDE OF S FACING BLOWER (1) (3) (4) DIN RAIL MOUNTED S (2) (10) (6) (7) (8) (9) HIM HIM BEZEL (15) (16) (11) (12) 15A FUSE 15A FUSE 15A FUSE 1N.O. (15) 1COM (16) GREEN TEMPERATURE CONTROLLER FAN + - FAN (8) (9) AC1 (13) AC2 (14) (12).6A FUSE (11).6A FUSE H1 H2 H3 H4 XF (13) 1A FUSE SEE NOTE 4 X1 TRANSFORMER X2 (14) T1 T2 T3 WHITE ORANGE L1 DISCONNECT SWITCH L2 L3 GREEN GREEN (6) (10) (7) PILOT LIGHT WIRES WITHOUT COLOR ARE BLACK FIELD LINE WIRING FIELD GROUND WIRING (INTERNAL) FIELD GROUND WIRING (EXTERNAL) blower and signal schematic ACE20 WIRING IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 6

7 R/L1 S/L2 T/L3 VARIABLE FREQUENCY DRIVE I/O U/T1 V/T2 W/T3 PE (19) (17) (18) (21) (24) (23) ACE20 PT RR3 WIRING + 4 TO 20 ma (CUSTOMER PROVIDED SPEED CONTROL INPUT) (19) (17) (18) POTENTIOMETER 4 TO 20 ma (CUSTOMER PROVIDED SPEED CONTROL INPUT) THIS SIDE OF FACING BLOWER DIN RAIL MOUNTED 9 BROWN GREY (20) (20) H O A (21) (22) GREY (22) HAND-OFF-AUTO (23) SWITCH (24) WIRES WITHOUT COLOR ARE BLACK AUTO RUN CONTACT - IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 7

8 R/L1 S/L2 T/L3 VARIABLE FREQUENCY DRIVE I/O U/T1 V/T2 W/T3 PE ACE20 PT PB23 WIRING (19) (17) (19) (17) POTENTIOMETER (18) (18) (26) THIS SIDE OF FACING BLOWER (25) 9 DIN RAIL MOUNTED (26) N.C. (25) (27) PUSHBUTTON STOP (27) N.O. PUSHBUTTON START IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 8

9 BLACK BLACK PILOT LIGHT GREEN PILOT LIGHT WHITE WHITE L1 L2 L3 VARIABLE FREQUENCY DRIVE I/O T1 T2 T3 FIELD LOAD WIRING (1) (2) (3) (4) (5) (6) BLOWER ACE30 WIRING L1 L2 L3 W/ GREEN STRIPE THIS SIDE OF S FACING BLOWER DIN RAIL MOUNTED S 1-6 WIRING FOR SIZE 2 ENCLOSURE ONLY NOT REQUI ON SIZE 1 ENCLOSURE ORANGE DIN RAIL MOUNTED S 7-12 (5) (7) (3) (8) THIS SIDE OF S FACING BLOWER (1) (2) (6) (4) (9) HIM (15) (16) (11) (12) 1N.O. (15) 1COM (16) 15A FUSE 15A FUSE 15A FUSE GREEN (12).6A FUSE (11).6A FUSE AC1 (13) H1 H2 H3 H4 TEMPERATURE CONTROLLER TRANSFORMER XF (13) 1A FUSE SEE NOTE 4 X1 AC2 (14) X2 (14) T1 T2 T3 WHITE ORANGE L1 DISCONNECT SWITCH L2 L3 GREEN GREEN (7) (9) (8) PILOT LIGHT WIRES WITHOUT COLOR ARE BLACK FIELD LINE WIRING FIELD GROUND WIRING (INTERNAL) FIELD GROUND WIRING (EXTERNAL) IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 9

10 R/L1 S/L2 T/L3 VARIABLE FREQUENCY DRIVE I/O U/T1 V/T2 W/T3 PE (20) (23) (18) (19) (17) THIS SIDE OF S FACING BLOWER (20) H O HAND-OFF-AUTO SWITCH 10 (24) DIN RAIL MOUNTED 4 TO 20 ma (CUSTOMER PROVIDED SPEED CONTROL INPUT) + A (21) (22) (23) BROWN ACE30 PT RR3 WIRING GREY (22) (21) (24) BROWN (19) (17) (18) POTENTIOMETER WIRES WITHOUT COLOR ARE BLACK AUTO RUN CONTACT - IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 10

11 R/L1 S/L2 T/L3 VARIABLE FREQUENCY DRIVE I/O U/T1 V/T2 W/T3 PE (25) (26) (27) (18) (19) (17) (17) (26) N.C. PUSHBUTTON STOP (25) N.O. PUSHBUTTON START (19) POTENTIOMETER WIRES WITHOUT COLOR ARE BLACK ACE30 PT PB23 WIRING (27) (18) IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 11

12 4. general operation 4.1 CONTROL PAD VIEWING WINDOW 4.3 COMMUNICATION MODULES Available Options: Protocol cat. # Suffix Profibus CP Devicenet CD CAN Open CC ACE20 Only Modbus CM Ethernet CE Wireless WL ACE20 Only Refer to the drive manufacturer s manual for information regarding communication module and WIM installation and use. The control pad viewing window shows the control pad display containing such information as drive status and operating data. Refer to the drive manufacturer s manual for information regarding the control pad display. 4.2 disconnect and lockout/tagout The disconnect handle is furnished with three (3) holes for lockout/tagout purposes. 1. Turn handle to the off position. 2. Depress lockout tab at the end of the handle. 3. Install OSHA approved lock or tag. 4. Release lockout tab. warning To avoid ignition of explosive atmospheres, all circuits must be de-energized before opening cover. Lockout Tab 4.4 pot, rr3 (hoa) and pb23 (PUSHBUTTON START/ STOP) Potentiometer, RR3, and PB23 options, when ordered, get wired to the drive for additional user control. Parameters for these options are set up at the factory. Refer to drive manufacturer s manual for further information as well as parameters in Section MAINTENANCE caution To avoid cooling system malfunction and cooling system failure, be sure to vacuum debris from the enclosure before energizing. NEVER use forced air for the removal of debris from this enclosure. 5.1 DRIVE MAINTENANCE Periodic cleaning of the drive fan and heat sink is recommended. Removal of the drive from the enclosure is recommended to ensure debris does not obstruct the cooling system. Refer to the drive manufacturer s manual for additional maintenance recommendations and specific instructions. 5.2 cooling system maintenance 1. Clean pre-filter periodically (recommended per parameters and values below). Remove pre-filter and rinse with water as needed. Parameter Number Parameter Type 2. Clean sintered filter as needed. Use of abrasives on the explosionproof filters may compromise the integrity of the cooling system. 3. Clean/inspect blower intake. Parameter Description Testpoint Code Maintenance Check Point ACE Utility Testpoint 1 Sel 2 (Heat Sink Temperature) 235 Utility Testpoint 1 Data Utility Testpoint 2 Sel 37 (Control Board Temperature) 237 Utility Testpoint 2 Data 72 ACE30 U4-08 Maintenance Monitors Heat Sink Temperature 105 caution To avoid damage to the integral disconnect operating mechanism, be sure the disconnect coupling is in the off position before closing cover. Disconnect Shaft Disconnect Coupling OFF Position 4. For ACE20 (Rockwell VFD), clean/inspect muffin fan. 5. Clean/inspect temperature controller. 6. Perform visual, electrical, and mechanical checks on all components on a regular maintenance schedule. NFPA 70B recommends maintenance intervals not exceeding 2 months. 7. Visually check for any damage to the filter assemblies, flat joints, threaded joints, journal joints, and window. 8. Visually check for evidence of excessive heating within the enclosure. 9. Mechanically check that all parts are properly assembled and operating mechanisms are in proper working condition. 10. Verify airflow provisions are maintained per Section 2.1. Blower Intake IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 12

13 5.3 periodic mechanical maintenance (torque verification) Torque Requirements Item Description Wire Range Torque Required ACE20 Drive (0.5-5 HP) Line/Load & Ground 18-6 AWG ( mm 2 ) 12 in.-lbs. (1.4 N-m) ACE20 Drive ( HP) Line/Load & Ground 18-6 AWG ( mm 2 ) 12 in.-lbs. (1.4 N-m) ACE20 Drive (25-50 HP) Line/Load & Ground 14-3 AWG ( mm 2 ) 16 in.-lbs. (1.8 N-m) ACE30 Drive ( HP) Line/Load AWG ( mm 2 ) 12 in.-lbs. (1.4 N-m) ACE30 Drive ( HP) Line 8-6 AWG ( mm 2 ) 25 in.-lbs. (2.8 N-m) Load 10-6 AWG ( mm 2 ) 25 in.-lbs. (2.8 N-m) Ground 10-8 AWG ( mm 2 ) 45 in.-lbs. (5.1 N-m) ACE30 Drive (25-30 HP) Line/Load 6-4 AWG ( mm 2 ) 50 in.-lbs. (5.7 N-m) Ground 8-6 AWG ( mm 2 ) 45 in.-lbs. (5.1 N-m) Drive Control (I/O) ACE20 Drive AWG ( mm 2 ) 5.2 in.-lbs. (0.59 N-m) ACE30 Drive AWG ( mm 2 ) 4.8 in.-lbs. (0.54 N-m) Disconnect 30 Amp 18-8 AWG ( mm 2 ) 17 in.-lbs. (1.9 N-m) 60 Amp 14-4 AWG ( mm 2 ) 30 in.-lbs. (3.4 N-m) 100 Amp 14-2/0 AWG ( mm 2 ) 120 in.-lbs. (13.5 N-m) Blower Fuse Block AWG ( mm 2 ) 20 in.-lbs. (2.3 N-m) Terminal Blocks 24-8 AWG ( mm 2 ) 8 in.-lbs. (0.9 N-m) Temperature Controller AWG ( mm 2 ) 5 in.-lbs. (0.54 N-m) Transformer AWG ( mm 2 ) 12 in.-lbs. (1.4 N-m) Internal Ground Lug 16-2/0 AWG ( mm 2 ) 120 in.-lbs. (13.5 N-m) External Ground Lug 6-1/0 AWG ( mm 2 ) 50 in.-lbs. (5.6 N-m) Blower Manifold N/A 20 in.-lbs. (2.3 N-m) Hose Clamps N/A 20 in.-lbs. (2.3 N-m) Cover Bolts N/A 45 ft.-lbs. (61 N-m) 5.4 status indication There are two lights for the status indicator - a GREEN light to signify RUN and a light to signify STOP or fault condition. When both lights are off, this indicates the power is off to the drive. 6. technical data 6.1 technical data chart Max. Max. Discon. Input Power Temp. CC-H Base Encl. Discon. Nominal Output Temp. Fuse Rating Loss Derating Cat. # Size Rating HP Rating Rating Type (Amps) (Watts) Factor (Amps) (Amps) VFD Mfg. Part # *ACE T6 N/A *ACE T6 N/A *ACE T6 N/A 20BD027A0AYNANC0 *ACE T6 N/A 1 30 J *ACE T6 N/A *ACE T6 N/A *ACE T6 N/A 20BE022A0AYNANC0 *ACE T6 N/A *ACE T4A N/A 30 J ACE T4A N/A 20BD027A0AYNANC0 ACE T4A N/A ACE T4A N/A 2 60 J ACE T4A N/A ACE T4A N/A 20BD065A0AYNANC0 ACE T4A N/A 100 J ACE T4A Figure 4 *ACE T6 N/A *ACE T6 N/A ACE T6 N/A CIMR-AU4A0009FUA ACE J T6 N/A *ACE T6 N/A ACE T6 N/A CIMR-AU5A0006FUA ACE T6 N/A *ACE T4A N/A 30 J ACE T4A N/A CIMR-AU4A0031FUA ACE T4A N/A 2 ACE T4A N/A 60 J ACE T4A N/A CIMR-AU4A0044FUA ACE T4A N/A *Additional motor overload protection is required between VFD output and motor due to oversized VFD used. For other catalogs and setups refer to section 3.3 of this manual. **Modified product designs may vary in terms of technical information. Contact factory for additional information. 6.2 power loss (heat dissipation) When the ACE Series enclosure is not installed in a well ventilated area, provisions must be made to account for heat generation and ensure proper operation of the device. 6.3 de-rating factors and curves (ambient temperature, altitude, switching frequency) The final drive output rating is a multiplication of all applicable de-rating factors. Ambient Temperature De-rating 5.5 explosive event required maintenance In the event of an explosion within the enclosure, the filter assemblies and pre-filters must be replaced. Personnel injury or equipment damage may result from failure to replace the filters with new filters after an explosion occurs within the enclosure. Inspect all other components and verify that they are in proper operating condition. Consult Crouse-Hinds for replacement parts as needed. Altitude and Switching Frequency De-rating: Refer to the drive manufacturer s de-rating guidelines for altitude and switching frequency and ensure compliance. WARNING: burn hazard To avoid personnel injury, allow sufficient time for the enclosure to cool prior to servicing. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 13

14 7. crouse-hinds drive parameters 7.1 parameter table Parameter Number Parameter Type Parameter Value Parameter Description ACE Utility Parameter Access Level 1 (Advanced) 151 Dynamic Control PWM Frequency 2 (2 khz) ACE20 RR3 (HOA) 196 Utility Parameter Access Level 1 (Advanced) 320 Inputs & Outputs Analog Input Configuration Bit 0 = 1 (Current) Tuning Carrier Frequency 1 (2 khz) ACE30 C6-02 ACE30 RR3 (HOA) A1-03 Initialization Initialize Parameters 2220 H3-02 Terminal Functions Terminal A1 Function Selection 2 H3-06 Terminal Functions Terminal A3 Function Selection F Initialize Parameters Be sure to stretch pre-filter elastic band completely around the explosionproof filter and seat the elastic band on the filter s threads. This will ensure all air flow to the bottom filters passes through the pre-filters. ACE30 PB23 (Pushbutton Start/Stop) A1-03 Initialization Explosionproof Filter To ensure cooling system performance, these parameters must be maintained at all times while observing the appropriate de-rating factors. 8. replacement parts ACE Series systems are designed to provide years of reliable service. However, should the need for replacement parts arise, they are available through your CrouseHinds Distributor. Assistance may also be obtained through your Crouse-Hinds Sales 8.2 SINTE FILTER kit Representative or the Crouse-Hinds Customer Service Department. ACE KIT2: Filter Assembly (1 pc.) 8.1 pre-filter kit sintered filter installation instructions ACE KIT1: Pre-filter and Hardware (1 pc.) pre-filter installation instructions 1. Remove rubber caps from explosionproof filters. 2. Install wire guard using the bracket, screw, and lock washer provided to the bottom filter(s). 3. Align guard with notches within the bracket as shown. Notch Bracket Filter Shrouds 1. Remove shroud and pre-filters and place all parts in a secure area. 2. Using a 1 socket wrench, remove all filters from the enclosure (top and bottom). 3. Remove rubber caps from explosionproof filters. 4. Apply thread grease to threads of explosionproof filters. 5. Install new filters (top and bottom) and torque each to 133 ft.-lbs. (180 N-m). 6. Install pre-filters and shrouds; refer to Sections 2.6 and 2.7. Guard Detail View 4. Tighten screw. 5. Slip pre-filter mesh over guard. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 14

15 8.3 blower kit ACE KIT3: Blower, Manifold, and Hardware (1 pc.) blower installation instructions 1. Disconnect blower power, ground, and control leads from terminal blocks (refer to wiring diagrams in Section 3.5). 10. Align new manifold clamp bracket to threaded studs. Be sure the manifold clamp bracket flanges point toward the interior of the enclosure. 11. Install four (4) lock washers and nuts on threaded studs hand tight before applying required torque. Tighten to 20 in.-lbs. DO NOT over-tighten. 12. Slide new blower/bracket assembly into place until fully seated, aligning to the threaded studs and the manifold. caution To avoid system malfunction and electrical shock, be sure that all wires are aligned in the baffle s wire pass through. 13. Tighten nuts wrench tight. 14. Tighten manifold hose clamp, while compressing the manifold to the blower, to 20 in.-lbs. 15. Re-attach blower cooling intake and tighten hose clamp to 20 in-lbs. Be sure to align bottom of blower cooling intake to the explosionproof filter at the bottom of the enclosure. 2. Loosen five (5) nuts holding blower bracket and baffle to mounting plate. DO NOT remove. 3. Loosen and remove manifold clamp bracket nuts and lock washers. DO NOT remove jam nuts positioned behind the manifold clamp bracket. Blower Cooling Intake Manifold Clamp Bracket Loosen and DO NOT remove nut during replacement 16. Terminate the blower power wires to the appropriate terminal block connections (refer to wiring diagrams in Section 3.5). 17. Perform a continuity check between each blower power terminal and each phase of the integral disconnect switch. 18. Terminate the blower control wires to the appropriate terminal block connections (refer to wiring diagrams in Section 3.5). 19. Perform a continuity check between each blower control terminal and the temperature controller (refer to wiring diagrams in Section 3.5). 4. Remove blower and brackets. 5. Remove manifold and manifold clamp bracket. 6. Remove blower cooling intake and hose clamp from old blower assembly and hold for re-assembly. 20. Terminate the blower ground wire to the appropriate terminal block connection (refer to wiring diagrams in Section 3.5). 21. Perform a continuity check between the ground terminal and the ground lug adjacent to the integral disconnect switch. 7. Loosen and remove three (3) screws and washers holding the baffle and plug plate to the blower bracket. Remove baffle and plug plate and hold for re-assembly. 8. Attach baffle and plug plate to new blower bracket using the same three (3) screws and washers. 9. Align new manifold to enclosure wall. IF /14 Copyright 2014, Eaton s Crouse-Hinds Business Page 15

16 8.4 TEMPERATURE CONTROLLER ACE KIT5: Temperature Controller TEMPERATURE CONTROLLER installation instructions 1. Disconnect wire terminals from temperature controller. Do not remove wires from terminals. 2. Loosen two (2) nuts holding the temperature controller to the mounting plate. Do not remove. 3. Remove temperature controller. 4. Insert new temperature controller into place on mounting plate and tighten two (2) nuts down wrench tight. 5. Reconnect wire terminals to the temperature controller, ensuring terminals are fully inserted. All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable.the accuracy or completeness thereof are not guaranteed. In accordance with Crouse-Hinds Terms and Conditions of Sale, and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability whatsoever in connection therewith. Eaton s Crouse-Hinds Business IF Wolf Street, Syracuse, New York U.S.A. Revision 3 Copyright 2014 Revised 01/14 Supersedes 12/13